Plasticised curable mixtures of polyepoxides and polyepoxidepolyamine adducts



United States Patent "ice 3547369 Patented Dec. 15, 1970 3 547 869 as resorcinol, bis-(p-hydroxyphenyl)-methane,2,2 bis- (p-hydroxyphenyl) propane (=diomethane or bisphenol PLASTICISED CURABLE MIXTURES 0F POLY- A) 22 bis(4' hydmxy 3,s, dibromophenyl) pmpane,

EPOXIDES AND POLYEPOXIDEPOLYAMINE l,l,2,2 tetrakis (p hydroXylphenyD-ethane or conhg i 3 3 Arlesheim, and Alfred Heel. Birsfelden densation products of phenols with formaldehyde obtained Switzerland, assignors to Ciba Limited, Basel, swit under acid conditions, such as phenol novolacs and cresol land, a company of Switzerland IIOVOIQCS- No Drawing. Filed Apr. 22, 1969, Ser. No. 818,436 Particularly suitable components (a) are the poly- Claims P y, pp z gg fgg i y 1963, glycidyl ethers of bisphenol A which are solid at room 9 ra Int- CL g 51/26 10 gesrgpgootslre and have an epoxide equlvalent welght of US. Cl. 26030.4 10 Claims Possible plasticising components (b) are firstly diglycidyl ethers of polyethylene glycols or polypropylene glycols of average molecular weight 300-1 10 0, for ex- ABSTRACT OF THE DISCLOSURE ample polypropylene glycol of average molecular weight PlasliCiZBd, curable mixtufs containing a 1025 or polypropylene glycol of average molecular weight polyglycidyl ether of a polyphenol, (2) as plasticizing 425 Component, a diglycidyl ether ester of a Polyethylene Further possible plasticising components are the diglycg y of p yp py glycol having an average molec' idyl esters of dicarboxylic acids of formula ular weight of at least 300 and at most 1100, for example diglycidyl ether of a polypropylene glycol having an dicarboxylic acid obtained by reacting 2 mols of phthalic wherein the residues R and A have the same significance anhy ri e W 1 mOl of p yp py glycol having an as in Formula I. Such dicarboxylic acids can for example average molecular weight of 425, and (3) a solvent-free be manufactured according to known processes by r adduct curing agent formed from (a) a polyglycidyl action of 2 mols of phthalic anhydride or tetrachloroether, which is liquid at room temperature, of a polyphthalic anhydride with 1 mol of a polyethylene glycol phenol, and (b) hexamethylene diamine or a mixture of or polypropylene glycol of average molecular Weight 300 hexamethylene diamine and a hexarnethylene diamine or 1100. No cover is here claimed for the diglycidyl esters of heptamethylene diamine alkyl-substituted in the polythese dicarboxylic acids (II), which have hitherto not methylene chain, there being used for the formation of been previously described in the literature.

the adduct a ratio of 3 to 12, preferably about 5, amino The adduct curing agents (c) are manufactured by regroup equivalents of the diamine or the diamine mixture acting (l) a polyglycidyl ether of a polyphenol, which is for every epoxide group equivalent of the polyglycidyl liquid at room temperature with (2) hexamethylenediether (a). amine or a mixture of hexamethylenediamine and a hexamethylenediamine or heptamethylenediamine which is alkyl-substituted in the polymethylene chain, in a pro- The subject of the present invention is new plasticised portion of 3 to 12, preferably about 5, amino group curable mixtures which are suitable for the manufacture equivalents of the diamine (2) per 1 epoxide group of shaped articles, impregnations, coatings and adhesive equivalent of the polyglycidyl ether (1) in the absence bonds and which are characterised in that they contain of solvents, with warming. The polyglycidyl ethers which (a) a polyglycidyl ether of a polyphenol, (b) as the are liquid at room temperature, that is to say 25 C., can plasticising component, a diglycidyl ether or diglycidyl be derived from polyphenols such as resorcinol, phenolester of formula formaldehyde condensation products of the type of the CHzOHCHz-O- d-A-C-O:|R OfAfi OCHiCHGH2 \O/ g zl L (I) O z] \O/ (I) wherein R denotes the residue, obtained by removing the cresols or novolacs, bis-(p-hydroxyphenyl)-methane and hydroxyl groups, of apolyethylene glycol or polypropylene especially 2,2 bis-(p-hydroxyphenyl)propane (=dioglycol of average molecular Weight of at least 300 and at methane or bisphenol A). most 1100, A represents a phenylene residue which is Compounds to be especially mentioned here are the either unsubstitued or substituted by halogen atoms and polyglycidyl ethers of diomethane which are liquid at z is an integer having a value of 1 or 2, and (c) as the room temperature, have an epoxide content of 3.8-5.8

curing agent, asolvent-free adduct which is liquid at room epoxide equivalents/kg. and correspond to the average temperature, from 1) a polyglycidyl ether, which is formula:

liquid at room temperature, of a polyphenol and (2) wherein n denotes a number having a value of O to 0.65. hexamethylenediarnine 01' a mixture of hexamethylenedi- To form an adduct with the above-mentioned liquid amine and a hexamethylenediamine or heptamethylenedipolyglycidyl ethers of polyphenols there are used, in adamine which is alkyl-substituted in the polymethylene dition to hexamethylenediamine alone, also its mixtures chain, with a proportion of 3 to 12, preferably about 5, with a hexamethylenediamine or heptamethylenediamine amine group equivalents of the diamine or of the diamine which is alkyl-substituted in the polymethylene chain, mixture (2) having been employed per 1 epoxide group such as for example 1,6-diamino-2,2,4-trimethylhexane, equivalent of the polyglycidyl ether (1) for the forma- 1,6 diamino 2,4,4-trimethylhexane and the industrial tion of the adduct mentioned. mixtures of these two isomers, and also 2-methyl-hex- As component (a) it is possible to use the known diglycamethylenediamine, 3 methyl hexamethylenediamine; idyl or polyglycidyl ethers, which are liquid or solid and 2,3-, 2,4-, 2,5- and 3,4-dimethylhexamethylenediamine fusible at room temperature, of polyhydric phenols such and 1,7 diamino 4,4 dimethylheptane. The polyamine which is alkyl-substituted in the polymethylene chain can also only be added to the adduct after its formation from hexamethylenediamnie and polyglycidyl ether.

The adduct curing agents (c) manufactured in this way are liquid at room temperature and do not tend to crystallise even at temperatures of about C. No cover is here claimed for these adducts which have hitherto not been previously described in the literature.

The adduct (c) is appropriately used in an approximately equivalent amount (that is to say 1 equivalent of amine hydrogen atoms of the adduct curing agent per 1 epoxide group equivalent of the mixture of the glycidyl components (a) and (b)).

Advantageously, a phenol or polyphenol, such as for example diomethane, can be added as a cure accelerator to the adduct curing agent in any phase of its manufacture, and 0 to 20% of a high-boiling liquid diluent such as for example dibutyl phthalate or polypropylene glycol of average molecular weight 300 to 1100 can be added to lower the viscosity.

The curable mixtures according to the invention can furthermore, before cure, be mixed at any stage with the usual modifiers such as extenders, fillers and reinforcing agents, pigments, dyestuffs, fiow control agents, agents for conferring thixotropy, fiameproofing substances or mould release agents.

As extenders, reinforcing agents, fillers and pigments which can be employed in the curable mixtures according to the invention there may for example be mentioned: glass fibres, boro fibres, cellulose, polyethylene powder, polypropylene powder, mica, asbestos, quartz powder, slate powder, hydrated aluminium trioxide, chalk powder, gypsum, antimony trioxide, bentones, silica aerogel (Aerosil), lithopone, barite, titanium dioxide, carbon black, graphite, iron oxide or metal powder such as aluminium powder or iron powder.

The term cure as used here denotes the conversion of the above mixtures into insoluble and infusible crosslinked products, and in fact as a rule with simultaneous shaping. At the same time the curable mixtures according to the invention are above all suitable for use as sealers, as sealing compositions or as joint filling materials, which after cure must be able to withstand blows and knocks and to neutralise the forces thus generated by reversible deformation. They are suitable for the manufacture for insulations against seepage water and pressure water in constructing shafts and tunnels, but also for coatings, floor coverings, castings, sound-insulating or sound-damping coatings or vibration-damping supports.

In the examples which follow, unless otherwise stated, the parts denote parts by weight and the percentages denote percentages by weight. The relationship of the parts by volume to the parts by weight is as of a millilitre to a gram.

The test methods employed in the examples which follow are specified below.

The modulus of elasticity, subsequently referred to as E-modulus for brevity, was determined according to DIN 53571 on 7 day old shoulder specimens, shape A, in a tensile test. In order to determine the E-modulus the samples were loaded in stages. The extension of a measuring distance of about 20 mm. which had beforehand been drawn in and measured, was measured every 2 minutes after reaching the load stage, using a travelling microscope (accuracy of reading 1/100 mm.). The E- modulus was calculated from the difference in tension between two load stages 0' and 0' and the difference in elongation e e corresponding to the difference in tension, using The tensile strength was determined according to DIN 53571 using specimens of shape A, in a mechanical 4 tensile testing machine in the 20 kp. range, with a speed of travel of 20 mm./minute.

In order to determine the elongation at break, again according to DIN 53571, using specimens of shape A, a test was additionally carried out at speeds of travel of and 300 mm./minute.

The depth of impression (boss impression) was determined on circular 4 mm. thick sheet specimens by a test derived from DIN 51955. Deviating from the test standard specification, the load weight was varied between 10 and 50 kp. A cylinder of 11.3 mm. diameter (:1 cm?) with a plane base surface and broken edges was used as the impression boss.

In the case of the water absorption, 4 mm. thick sheets of size 10 x 10 cm. were stored in tap water and the water absorption was determined gravimetrically.

The water vapour permeability was determined according to DIN 53122 (preliminary standard specification, April 1961) using circular 4 mm. thick sheets of 9 cm. diameter. Finely granular calcium chloride served as the absorbent. The relative atmospheric humidity of 2% was established in the vapourisation chamber by means of a saturated potassium chloride solution. The experiments ran for 44 days. The mean water vapour permeability is specified in g./m. d (days).

The behaviour towards pressure water was determined as follows: the experiments were carried out on 4 mm. thick sheets using a water pressure of 20 kp./cm. For the test, one sheet specimen at a time, of diameter about 20 cm., was clamped centrally between 2 steel plates (external diameter 30 cm.). The circular test area exposed to the water pressure had a diameter of mm. (=78.5 cm. test area).

A 5 mm. thick circular disc of pine wood, again of 100 mm. diameter, which had been climatically conditioned in standard climatic conditions DIN 50014 (2011" C. and 65 :5% relative humidity) was inserted into the recess of the lower steel plate under the sheet area subjected to the water pressure. As a result of the hygroscopic properties of the wood this disc can absorb the water which may have penetrated through the sheet.

The amount of water which has penetrated through the sheet can be determined by weighing the pine wood disc before and after the test.

The following epoxide resins were used for the manufacture of plasticised curable epoxide resin mixtures described in the examples:

EPOXIDE RESIN A Solid diomethane polyglycidyl ether manufactured by condensation of epichlorhydrin with diomethane (2,2- bis-(p-hydroxyphenyl)-propane) in the presence of alkali, having the following characteristics: epoxide content: 2.0-2.5 epoxide equivalents/kg. softening point (Durran): 60 65 C.

EPOXIDE RESIN B Polyglycidyl ether resin manufactured by a condensation of a stoichiometric excess of epichlorhydrin with diomethane in the presence of alkali, consisting mainly of diomethane diglycidyl ether and liquid at room temperature, having the following characteristics: epoxide content: 5.3 epoxide equivalents/kg. viscosity at 25 0.: 10,000 cp.

EPOXIDE RESIN C (PLASTICISER) Diglycidyl ether of a polypropylene glycol of average molecular weight 425, having the following characteristics:

epoxide content: 2.26 epoxide equivalents/kg. viscosity at 25 0.: about cp.

EPOXIDE RESIN D (PLASTICISER) Diglycidyl ester of the condensation product of 2 mols of phthallc anhydride and 1 mol of polypropylene glycol of average molecular weight 425, having the following characteristics:

epoxide content: 2.3 epoxide equivalents/kg. viscosity at 25 C.: 3000 cp.

Epoxide resin D can be manufactured as follows:

(a) Manufacture of the half-ester 593 g. (4 mols) of phthalic anhydride and 850 g. of polypropylene glycol of mean molecular weight 425 are initially introduced into a suitable reaction vessel and warmed to 130 C. whilst stirring. A slight exothermic reaction starts. After 3 hours at 1l5-120 C. the mixture is cooled to 90 C. and a sample is triturated to determine the acid content. The trituration showed 2.6 equivalents/ kg. of free carboxyl groups (theory 2.77 equivalents/kg.) and 0.2 mol/kg. of unchanged phthalic anhydride.

(b) The intermediate product is mixed with 2220 g. (24 mols) of epichlorhydrin in the same reaction vessel and the temperature is kept at 90 C. 20 g. of a 50% strength aqueous solution of tetramethylammonium chloride are introduced and this initiates an exothermic but easily controllable reaction. The temperature is kept between 88 and 92 C. The course of the reaction is monitored with the aid of a pH-electrode. The pH measuring equipment initially shows a pH-value of 3.5-4.5 which rises slowly and is about 7 after 20 minutes. After 20 to 25 minutes an abrupt rise in the pH-value occurs which indicates the end of the reaction. The pH-electrode is removed and a dropping funnel with 400 g. mols: 125% of the theoretical amount) of aqueous 50% strength sodium hydroxide solution is attached. The reaction mixture is cooled to 5060 C. and a further g. of aqueous 50% strength tetramethylammonium chloride solution are added. The apparatus is subjected to vacuum. The sodium hydroxide solution is allowed to run in continuously over the course of 80 to 120 minutes at a vacuum of 70100 mm. Hg and an internal temperature of 52-5 8 C., in the course of which the water introduced and the Water formed are distilled off azeotropically with epichlorhydrin. The epichlorhydrin separated from the water in a water separator is continuously returned to the reaction mixture. About 300 ml. of water are separated off. For working up, air is admitted into the apparatus and the reaction mixture is successively Washed in a separating funnel with 1000 ml. of water, with 700 ml. of aqueous 5% strength monosodium phosphate solution and with 700 ml. of water. The epichlorhydrin solution is concentrated in vacuo (water pump) in a rotational evaporator. The residue is dried for 45 minutes at 120 C. and a vacuum of 1-2 mm. Hg and is then filtered through a pressure filter using filter paper.

1600 g. (96% of theory) of a yellow clear liquid noncrystallising product are obtained, giving the following analytical value:

viscosity (at C.): 3000 cp. (Hoeppler viscometer) epoxide content: 2.30 epoxide equivalents/kg. (95.6%

of theory) chlorine content: 0.6% (according to Wurzschmitt).

The product consists mainly of the diglycidyl ester of formula II O CHa n-7 (mean value) 0 L 1 Manufacture of amine adduct curing agent A (contains diomethane as accelerator).

94 parts by weight of a diomethane diglycidyl ether manufactured by condensation of epichlorhydrin with diomethane in the presence of alkali, which is liquid at room temperature and has an epoxide content of 5.4 epoxide equivalents/kg. and a viscosity of about 9000 cp. at 25 C. are introduced over the course of 60 minutes into a homogeneous melt of 164 parts by weight of hexamethylenediamine and parts by weight of diomethane (=2,2-bis(p -hydroxyphenyl) propane) at 80-90 C. After a further 30 minutes stirring at to C. 44 parts by weight of trimethylhexamethylenediamine (isomer mixture of 1,6-diamino-2,2,4-trimethylhexane and 1,6-diamino-2,4,4-trimethylhexane) are introduced. 397 parts of liquid noncrystallising adduct containing free diomethane as an accelerator (=amine adduct curing agent A), having a viscosity of about 3400 cp. at 25 C., are obtained as the product.

Example 1.-A homogeneous mixture is manufactured at 70-80 C. from 35 parts of epoxide resin A (solid diomethane polyglycidyl ether having an epoxide content of 2.0-2.5 epoxide equivalents per kg.) and 65 parts of epoxide resin C (liquid diglycidyl ether of polypropylene glycol 425 having an epoxide content of 2.26 epoxide equivalents/kg). 15 parts of the amine adduct curing agent A described above and containing diomethane as an accelerator are added at room temperature to 100 parts of this mixture. The resulting resin/ curing agent mixture is cast in aluminium moulds and cured for 24 hours at 25 C.

Clear highly elastic castings are obtained, having the following properties:

E-modulus: 43.5 kp./crn.

elongation at break: 45%

tensile strength: 10 kp./cm.

Pressure water test on 4 mm. thick sheets at 20 kp./cm.

water pressure: leakproof.

If the cure is effected at +5 C., the cure time increases to 48 hours.

Example 2.20.5 parts of asbestos powder are incorporated into 100 parts of the epoxide resin mixture of 35 parts of epoxide resin A and 65 parts of epoxide resin C (plasticiser) described in Example 1, and the mixture was homogenised in an intensive mixer. After adding 15 parts of amine adduct curing agent A as described in Example 1, the resin/curing agent mixture is introduced into aluminium moulds. The mass is fully cured at 25 C. after 24 hours and at 5 C. after 48 hours. After 7 days storage, castings having the following final properties are obtained:

E-modulus: 36.0 kp./cm.

tensile strength: 18 kp./cm.

elongation at break: 37%

boss impression up to damage: 20 kp./cm.

residual depth of impression after 24 hours load and subsequent release of load: 0 mm.

water absorption after days: about 4% water vapour permeability: 1.03 g./m. day

pressure water test on 4 mm. thick sheets at 20 kp./cm.

leakproof to pressure water.

Example 3.60 parts of asbestos powder and 2.0 parts of silica aerogel (registered trade name Aerosil) are worked into 100 parts of the epoxide resin mixture of 35 parts of epoxide resin A and 65 parts of epoxide resin C (plasticiser) described in Example 1, and the mixture is homogenised in an intensive mixer.

After adding 15 parts of amine adduct curing agent A as described in Example 1, the resin/curing agent mixture is introduced into aluminium moulds. The mass is fully cured at 25 C. in 24 hours and at 5 C. in 48 hours. After 7 days storage, castings having the following final properties are obtained:

tensile strength: 29 kp./cm.

elongation at break: 28%

E-modulus: 91 kp./cm.

boss impression up to damage: 30 lcp./cm.

residual depth of impression after 24 hours load and subsequent release of load: mm.

water absorption after 170 days: about 3% water vapour permeability: 0.75 g./m. day

pressure water test on 4 mm. thick sheets at kp./cm.

leakproof to pressure water.

mixture (2) must be employed per 1 epoxide group equivalent of the polyglycidyl ether (1).

2. A plasticised curable composition of matter which comprises (a) a polyglycidyl ether of a polyphenol, (b) as the plasticizer, a diglycidyl ether or diglycidyl ester of formula u. i L l. u.-.

Example 4.A homogeneous mixture is manufactured from 35 parts of epoxide resin B (liquid diomethane diglycidyl ether having an epoxide content of 5.3 epoxide equivalents per kg. and a viscosity at C. about 10,000 1 E-modulus: kp./cm.

elongation at break: 52%

tensile strength: 16 kp./cm.

water absorption after 12 weeks: 4.9% water vapour permeability: 1.2 g./m. day.

Example 5.-A homogeneous mixture is manufactured from 20 parts of epoxide resin B (liquid diomethane diglycidyl ether having an epoxide content of 5.3 epoxide equivalents/kg. and a viscosity of about 10,000 cp. at 25 C.) and 80 parts of epoxide resin D (liquid diglycidyl ester of the condensation product of 2 mols of phthalic anhydride and 1 mol of polypropylene glycol 425, having an epoxide contentof 2.3 epoxide equivalents/kg.) at -80 C. whilst stirring.

20 parts of the amine adduct curing agent A described above are added at room temperature to 100 parts of this mixture. The resin/curing agent mixture is cast into aluminium moulds. The cure time is 24 hours at 25 C. At 5 C. the cure time increases to 48 hours. Highly elastic castings having the following final properties are obtained after 7 days storage:

E-modulus: 18 kp./cm.

elongation at break: 128% tensile strength: 23 kp./cm.

Water absorption after 12 Weeks: 4.2%

Water vapour permeability: 0.65 g./m. day.

We claim:

1. A plasticised curable composition of matter which comprises (a) a polyglycidyl ether of a polyphenol, (b) as the plasticizer, a diglycidyl ether or diglycidyl ester of formula wherein R denotes the radical which is obtained by removing the hydroxyl groups from a polyethylene glycol or polypropylene glycol or average molecular weight of at least 300 and at most 1100, A represents unsubstituted or halogen substituted phenylene and z is an integer of at least 1 and at most 2, and (c) as the curing agent, a solvent-free adduct which is liquid at room temperature, said adduct being formed from (1) a polyglycidyl ether of a polyphenol, said ether being liquid at room temperature, and from (2) hexamethylenediamine or a mixture of hexamethylenediamine and of a hexamethylenediamine or heptamethylenediamine which is alkyl-substituted in the polymethylene chain, with the proviso that about 5 amine group equivalents of the diamine or of the diamine mixture (2) must be employed per 1 epoxide group equivalent of the polyglycidyl ether (1).

3. A curable composition as claimed in claim 1 which contains as component (a) a polyglycidyl ether of 2,2- bis(p-hydroxyphenyl)-propane which is solid at room temperature and has an epoxide equivalent Weight of 4. A curable composition as claimed in claim 1 which contains as component (b) the diglycidyl ether of a polypropylene glycol of average molecular weight 425. 0

5. A curable composition as claimed in claim 1 which contains as component (b) the diglycidyl ester of a dicarboxylic acid which is formed by reaction of 2 mols of phthalic anhydride with 1 mol of polypropylene glycol of average molecular weight 425.

6. A curable composition as claimed in claim 1 which contains as component (c) an adduct formed from a polyglycidyl ether of 2,2-bis (p-hydroxypheny1)-propane which is liquid at room temperature, and from hexamethylenediamine.

7. A curable composition as claimed in claim 1, wherein component (c) subsequent to the adduct formation has been diluted with a mixture of l,6-diamin0-2,2,4-trimethylhexane and 1,6-diamino-2,4,4-trimethylhexane.

8. A curable composition as claimed in claim 1 which contains as component (c), an adduct from a polyglycidyl ether of 2,2-bis (p-hydroxyphenyl) -propane which is liquid at room temperature and from the mixture of hexamethylenediamine, 1,6-diamine-2,2,4-trimethylhexane and 1,6- diamino-2,4,4-trimethylhexane.

9. A curable composition as claimed in claim 1 which in addition contains a monophenol or polyphenol as cure accelerators.

wherein R denotes the radical which is obtained by removing the hydroxyl groups from a polyethylene glycol or polypropylene glycol of average molecular weight of at least 300 and at most 1100, A represents unsubstituted or halogen substituted phenylene and z is an integer of at least 1 and at most 2, and (c) as the curing agent, a solvent-free adduct which is liquid at room temperature, said adduct being formed from (1) a polyglycidyl ether of a polyphenol, said ether being liquid at room temperature, and from (2) hexamethylenediamine or a mixture of hexamethylenediamine and of a hexamethylenediamine or heptamethylenediamine which is alkyl-substituted in the polymethylene chain, with the proviso that 3 to 12 amine group equivalents of the diamine or of the diamine UNITED STATES PATENTS 3,865,888 12/1958 Greenlee 2-6047(EpCN) 2,909,448 10/ 1959 Schroeder 26047(-EpCN)X 6/1969 McKay et a1. 260830(TW)X MORRIS LIEBMAN, Primary Examiner L. T. JACOBS, Assistant Examiner 

